If you've encountered an F2028 error code on your main auger servo drive, you're dealing with an over-torque fault. This is one of the most common calls I receive in technical support, and I've learned that the cause is usually split about 50/50 between mechanical issues and product-related problems.
Let me clear up a common misconception first: this isn't a safety feature for operators. It's a protection mechanism that prevents the machinery from destroying itself. Think of it as the machine's way of saying "something is seriously wrong" before damage occurs.
The good news? Most over-torque faults can be resolved by working through a systematic troubleshooting process. Let me walk you through exactly how I approach troubleshooting auger filler over-torque when customers call.
The 7 Steps for Troubleshooting Auger Filler Over-Torque Faults
Over-torque faults are frustrating, but they're usually solvable by working through this systematic approach:
1. Empty the hopper2. Check mechanical freedom
3. Verify alignment
4. Inspect tooling for damage
5. Check bushings and seals
6. Look for foreign objects
7. Confirm product compatibility
Step 1: Empty the Hopper
This might seem obvious, but you'd be surprised how often this solves the problem immediately. If you haven't already done so, completely empty the hopper of all product.
Sometimes product buildup, bridging or compaction inside the hopper creates enough resistance to trigger the fault. Before diving into mechanical diagnostics, start with a clean slate.
Step 2: Check Mechanical Freedom with Power Off
With the hopper empty and power completely off, try to turn the auger by hand with the tooling installed. It should rotate freely without significant resistance.
If the auger doesn't turn freely:
Remove the tooling completely and try rotating the spindle again. This simple test tells you whether the problem is with the tooling assembly or something deeper in the drive mechanism.
If the spindle turns freely with tooling removed, you've narrowed the issue to one of two possibilities:
- Tooling alignment problem
- Damaged or bent tooling
If the spindle still binds with tooling removed, the problem is in the hopper adapter, bushings or seals (we'll cover this a little later in Step 4).
Step 3: Verify Hopper Alignment
Proper hopper alignment is critical, and misalignment is one of the most common causes of torque faults I see.
Every Spee-Dee machine ships with an alignment tool specifically designed for this purpose. Unfortunately, thes parts often get misplaced. They don't look particularly important, so they get damaged or thrown away.
When alignment matters most:
Anytime you disassemble the hopper for cleaning, maintenance or product changeover, you must verify alignment when reassembling. Skipping this step is asking for trouble.
We have a detailed alignment procedure available, including a step-by-step YouTube video that walks through the entire process. If you've lost your alignment tool, contact us for a replacement before attempting to troubleshoot further.
Misalignment creates binding between the auger and hopper wall, forcing the servo to work harder and eventually triggering the over-torque protection.
Step 4: Inspect for Bent or Damaged Tooling
This issue is especially common in vertical form-fill-seal (VFFS) applications where tooling tends to be longer.
Even a slight bend in the auger will cause it to bind during rotation. Here's how to check:
1. Find a flat, level surface (a workbench or table works well)
2. Place the auger on the surface
3. Roll it slowly and watch for any hopping or jumping in the middle section
If the auger isn't rolling smoothly and evenly, it's bent. This creates intermittent contact with the hopper wall, generating friction spikes that trigger the fault.
If you're unsure whether your tooling is damaged, you can send it to us for inspection. We'll verify whether it's within spec or needs replacement.
Step 5: Check Bushings and Seals
If you've removed the tooling and the spindle still doesn't rotate freely, the problem is likely in the hopper adapter assembly.
The bushings and seals around the adapter shaft require regular maintenance. When customers neglect this:
- Seals wear down and lose effectiveness
- Bushings seize or develop excessive friction
- Resistance increases dramatically
- The servo faults out trying to overcome the friction
Replacement options:
If you need new bushings or seals, we can provide a quote for parts. You have two options for installation:
1. Send your spindle to us and we'll press in new bushings and seals
2. Take it to a local machine shop that can handle the work
Most customers find they can handle the replacement themselves with basic tools and some mechanical aptitude.
Step 6: Look for Foreign Objects
I've seen some surprising things cause over-torque faults. I'm talking about pieces of pallets wedged inside hoppers, cardboard chunks, plastic film, parts of upstream equipment and all sorts of debris that shouldn't be there.
Carefully inspect:
- The space between the auger and hopper wall
- Inside the tooling itself
- Around the adapter and any transition points
Anything lodged in these areas will create friction and binding. Even small objects can generate enough resistance to trigger the fault, especially if they're caught between rotating and stationary components.
Step 7: Verify Product Compatibility and Correct Tooling
This is where about half of my over-torque fault calls end up. The customer has introduced a new product, and they're trying to run it on tooling that wasn't designed for it.
Critical questions to ask:
- Is this a new product you haven't run before?
- Was the tooling specifically spec'd by Spee-Dee for this product?
- Are you using tooling designed for a different product?
If you're running new product on existing tooling, there's a good chance the tooling isn't appropriate for that product's characteristics.
When to Involve the Lab Team
If you've worked through these steps and still can't resolve the fault, that's when it's time to involve our lab team. We'll dig deeper into servo parameters, review your specific application and help identify any issues that aren't covered by standard troubleshooting.
Product compatibility issues require expertise beyond basic troubleshooting. This is when our lab team, led by Dennis Mulder (who just so happens to be my dad), gets involved.
The customer sends product samples to our facility. Dennis analyzes:
- Flow characteristics (free-flow vs. non-free-flow)
- Compression behavior
- Blow-test performance
- Particle size and consistency
Based on this analysis, we determine the correct specifications:
- Tooling style (free-flow, non-free-flow, vacuum, etc.)
- Auger pitch
- Tip configuration
Using incorrect tooling will absolutely cause over-torque faults. The auger has to work much harder to move product that doesn't match the tooling design, and eventually the servo's protection kicks in.
Product Testing for Borderline Cases
Most of the time, Dennis can recommend appropriate tooling just by touching the product, compressing it, performing a blow test and working with a small sample.
But when a product falls into a borderline category—especially scenarios that might require vacuum tooling—we conduct more extensive testing. Vacuum tooling represents a significant investment (typically $20,000 to $30,000), so customers understandably want solid validation before purchasing.
Real-World Example: Chelsea Milling (JIFFY Mix)
Let me share a recent example that illustrates how product and tooling compatibility can create unexpected challenges.
Chelsea Milling normally runs all non-free-flow tooling for their standard JIFFY Mix products. They wanted to introduce a new product: plain raw cornmeal with no fats or sugars. This product is more granular and free-flowing than their typical mixes.
For cornmeal with these characteristics, we recommend free-flow tooling. The problem? Their system was installed under extremely tight height constraints.
In typical VFFS installations—especially when integrated with Triangle forming sets—we leave vertical space between the hopper and forming set to accommodate the collector funnel that comes with free-flow tooling.
But in their installation:
- The ceiling was unusually low
- We had compressed the stack-up during initial installation
- We used a custom-length column and 90-degree motor
- There wasn't enough height remaining for free-flow tooling
Now we're evaluating several options:
- Installing a shorter hopper
- Working with Triangle to modify their forming set (they might be able to remove height from the forming shoulder)
- Raising the entire auger assembly on an adjustable-height column (they have about four inches before hitting the ceiling)
We're collaborating with Triangle and the customer to determine the best approach. While this situation is somewhat unusual due to the height restrictions, the process is typical: evaluate the new product, review tooling requirements, assess the physical constraints and work across teams to find a solution.
Need help addressing your auger over-torque faults?
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